US20130152994A1 - Solar Cell Combination - Google Patents

Solar Cell Combination Download PDF

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Publication number
US20130152994A1
US20130152994A1 US13/687,404 US201213687404A US2013152994A1 US 20130152994 A1 US20130152994 A1 US 20130152994A1 US 201213687404 A US201213687404 A US 201213687404A US 2013152994 A1 US2013152994 A1 US 2013152994A1
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Prior art keywords
solar cell
solar cells
wire conductors
contacted
wire
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Abandoned
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US13/687,404
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English (en)
Inventor
Matthias Schaarschmidt
Thilo Richter
Wolfgang Enger
Thomas Seidel
Paul Grunow
Martin KUTZER
Olaf Storbeck
Holger Neuhaus
Matthias Georgi
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SolarWorld Innovations GmbH
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SolarWorld Innovations GmbH
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Publication of US20130152994A1 publication Critical patent/US20130152994A1/en
Assigned to SOLARWORLD INNOVATIONS GMBH reassignment SOLARWORLD INNOVATIONS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GRUNOW, PAUL, RICHTER, THILO, STORBECK, OLAF, NEUHAS, HOLGER, ENGER, WOLFGANG, KUTZER, MARTIN, SCHAARSCHMIDT, MATTHIAS, SEIDEL, THOMAS, GEORGI, MATTHIAS
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the invention relates to a solar cell combination, wherein contacting the solar cells is carried out through wire conductors, and a plurality of solar cells are combined with each other through the wire conductors so as to form the solar cell combination.
  • a solar cell usually consists of a substrate having a front side and a back side, wherein a contact structure is applied onto at least one of the two sides.
  • the contact structure has a width of at least 100 ⁇ m, whereas its thickness is only approximately 10 to 15 ⁇ m.
  • a larger width causes a decrease of efficiency due to the resulting increased shading, whereas reducing the width results in the disadvantage that the line resistance of the contact structure is increased.
  • the current of the individual contact structures is fed into busbars causing further shading on the front side surface.
  • Connecting solar cells is generally carried out through contact ribbons that are soldered onto the busbars of the solar cell. All the current is fed through the contact ribbons. In order to keep the resistance losses as low as possible, a certain total cross-sectional area of these ribbons is required. The result of this is that there is a loss on the front side caused by the shading.
  • a problem here is the handling and positioning of the thin wires on the solar cell.
  • the series connection of the cells causes problems since—analogous to the solder ribbons of the standard soldering process—the wires have to be brought from the front side of the first solar cell to the back side of the second solar cell. This implies also that for contacting front and back sides, the same material has to be used.
  • a device for processing solar cells wherein individual solar cells are interconnected with electrical connectors so as to form a string.
  • the device comprises a connection strip receptacle, a soldering paste dispenser that applies the soldering paste onto the connection strips, at least one solar cell depositing rack as a soldering station, one turning device for the connection strips and one transport device from the turning device to the solar cell depositing station for depositing the connection strips onto the solar cells.
  • a solar cell comprising at least one semiconductor layer arranged on a metallic carrier and a multiplicity of contact paths arranged on the semiconductor layer is described in DE 10 2006 041 046 A1.
  • a lateral protrusion of at least one contact path is bent onto a back side of the carrier and is arranged electrically insulated with respect to the carrier.
  • Solar cells arranged next to each other are preferably connected to each other through strip conductors having a perforated configuration so as to enable local contacts by soldering through.
  • the carrier is formed here as a metal band, wherein the contact paths are arranged transverse to or along a longitudinal direction of the carrier, protrude laterally beyond the carrier band, and can be used in this manner for interconnecting. Furthermore, collecting paths are arranged transverse to the longitudinal direction and transverse to the contact paths and are electrically connected to the contact paths, and the contact paths as well as the collecting paths are glued in the region of the back side of the carrier.
  • the contact paths or collecting paths are implemented in the form of copper wire or copper band.
  • insulations implemented as edge insulations are arranged along the edge. Overall, structuring and connecting individual solar cells by using perforated strip conductors is problematic, and using edge insulations involves increased manufacturing-related expenses.
  • a wire system for electrically contacting a solar cell comprising a wire conductor that runs alternately between a first contacting section and a second contacting section arranged spaced apart from the first contacting section in such a manner that the wire conductor forms the wire system with a mesh-like arrangement which extends with a multitude of meshes along an extension direction, is known from DE 10 2007 022 877 A1.
  • the wire conductor is fixed in the mesh-like arrangement through fixing means provided in addition to the wire conductor, and/or through fixing means in the form of sections of the wire conductor, which section are wound around each other.
  • the wire conductor runs as an endless string periodically alternating back and forth along an extension direction between a first contacting section and a second contacting section.
  • the two contacting sections are regions of the wire system, which regions are equidistantly spaced apart from each other and run along the extension direction of the wire system.
  • two solar cells arranged next to each other have solar cell contacting sections which are arranged opposing each other in the adjoining edge regions of the solar cells and which are connected to each other through the mesh-like wire conductor.
  • an electrically insulating base insulator layer is provided in the solar cell contacting section of a solar cell, and an electrically insulating emitter insulator layer is provided in the adjacent solar cell so that a series connection is generated.
  • Producing the mesh-like wire conductor is relatively complicated. A significant disadvantage of this solution is also that the efficiency is negatively influenced because the areas for contacting between front side and back side are required in two dimensions.
  • the strings produced as a pre-stage for the assembly of modules have the disadvantage that the cells are put on individually and are covered with tin-plated copper band pieces which cover the cells and also extend below the next cell to be put on. These copper bands are soldered with different processes. This method requires preparation of the cells with a print image as solder connection material and as strip conductor for “collecting” the free electrons and transporting to the copper bands.
  • the strings are picked up by handling devices, aligned and assembled so as to form modules.
  • the assembled strings are electrically connected through cross-connectors so as to form a module.
  • the required connections are produced successively in individual process steps resulting in long production times.
  • an electrode for contacting an electrically conductive surface in particular at least one surface of a photovoltaic element, is known.
  • Said surface consists of an electrically insulating, optically transparent film, an adhesive layer applied onto a surface of said film, and a first group of substantially parallel, electrically conductive wires which are embedded in the adhesive layer, protrude with a portion of their surface from the adhesive layer, and, at least on the surface protruding from the adhesive layer, are coated with a layer having a low melting point, wherein the wires of the first group are electrically connected to a first contact strip.
  • a second group with wires running substantially parallel to each other is arranged between the transparent film and the wires of the first group, wherein the wires of the first and second groups together form a grid, and wherein the wires of the second group are electrically connected to a second contact strip.
  • this constructional configuration is very complicated.
  • the wires protrude irregularly from said adhesive layer or can also be completely covered by the adhesive, which can result in defects.
  • the film and the adhesive remain in the module; this implies relatively high demands in terms of long-term stability to be met by the adhesive and the film and therefore causes relatively high costs.
  • the prefabrication of electrodes from wire, optically transparent film and adhesive is technologically sophisticated.
  • a method for interconnecting solar cells by using prefabricated metal mesh e.g. aluminum gage
  • metal mesh e.g. aluminum gage
  • JP 59115576 A A method for interconnecting solar cells by using prefabricated metal mesh (e.g. aluminum gage) which is contacted with the surface of the cell on the front side and the back side.
  • the metal mesh Under the influence of pressure and temperature, the metal mesh is connected in each case to one cell by means of a heating unit. In the case of this solution, handling is relatively complicated.
  • a component which comprises a photosensitive semiconductor plate having a barrier structure, electrically conductive current collector contacts arranged on both sides of the semiconductor plate, and protective coatings and current dissipating electrodes arranged on both sides of the semiconductor plate.
  • At least the electrically conductive current collector contacts arranged on the front side of the semiconductor plate are implemented in the form of electrically connected and successive sections which are in contact or not in contact with the surface of the semiconductor plate.
  • the current collector contacts are made from a bent wire. This embodiment is very complicated and it can easily occur that the thin bent wire gets crushed.
  • connection materials cover an undesirably large portion of the usable silicon surface and thus deteriorate the efficiency of the solar cell.
  • Another object of the invention is to reduce the printed regions for the bars or strip conductors or to eliminate them completely.
  • the method for contacting and connecting solar cells for producing the solar cell combination according to the invention is carried out by means of at least two independent electrodes, wherein at least one electrode is formed from at least one or a plurality of wire conductors that are substantially parallel to each other, and after the contacting between solar cells and electrodes, establishing a series connection or parallel connection takes place by separating the wire conductors required for this at the required positions and by establishing the connection between the electrodes, wherein establishing the connection between the electrodes is implemented before or after separating.
  • contacting and connecting solar cells by means of wire conductors so as to form a solar cell combination is carried out, for example, in that in a manner as continuous as possible, a plurality of solar cells
  • the first wire conductors are contacted on the upper side of the solar cells, wherein then the further contact elements can be configured in the form of two electrical cross-connectors which run transverse to the first wire conductors, between adjacent solar cells, and are applied to the first wire conductors and are connected to them.
  • the first wire conductors are separated transverse to their longitudinal extension and parallel to the electrical cross-connectors between adjacent solar cells so that a stripe-like combination of solar cells with a protruding region of first contact elements and with the two cross-connectors is generated. This region is connected to the lower side of the adjacent solar cells so that at least one cross-connector is provided on the lower side of the adjacent solar cells and is now contacted with them.
  • first wire conductors are separated, transverse to their longitudinal extension and parallel to the cross-connectors, between adjacent solar cell(s) so that a stripe of solar cells is generated, which solar cells are connected to each other through the two cross-connectors, and which stripe has a protruding region with first wire conductors. Subsequently, the region of the first wire conductors protruding beyond the solar cell(s) is contacted with the cross-connectors on the lower side of adjacent solar cells.
  • first linearly running wire conductors are also contacted on the upper side of, in particular, a plurality of solar cells and that further contact elements are configured in the form of second wire conductors and also in the form of cross-connectors, wherein the second wire conductors run in particular linearly and are contacted on the lower side of the solar cells substantially parallel to the first wire conductors.
  • the first and the second wire conductors are connected to each other through the electrical cross-connectors, wherein the cross-connectors preferably run between the first and second wire conductors.
  • connections of the first wire conductor and the second wire conductor to the cross-connector are in each case alternately disconnected so that a series connection is created.
  • the preferably continuous first wire conductor(s) runs (run) alternately between the upper side and the lower side of adjacent solar cells.
  • the second contact elements are preferably configured in the form of continuously running second wire conductors which run substantially parallel to the first wire conductors, wherein the second wire conductors run alternately (opposite) to the first wire conductor(s) between the lower side and the upper side of adjacent solar cells.
  • the first wire conductors and the second wire conductors are preferably alternately disconnected between the solar cells in such a manner that likewise a series connection is created.
  • Disconnecting the first and/or the second wire conductor is carried out mechanically or preferably by means of laser.
  • successively arranged solar cells are connected to each other by a multiplicity of first wire conductors and/or second wire conductors and/or cross-connectors, which are arranged next to each other with regard to the longitudinal direction so that from the first wire conductors and/or the second wire conductors and/or cross-connectors in connection with the solar cells a kind of fabric is generated.
  • the ends of the first and/or second wire conductors and/or cross-connectors are provided with electrical collecting connectors for current collection.
  • establishing the contacting is carried out by means of conventional bonding technologies, e.g., by glueing, soldering or welding.
  • the solar cell combination is preferably produced such that said solar cell combination is separated into a plurality of strings or solar cell modules, or that it forms a solar cell module.
  • said solar cell combination is separated into a plurality of strings or solar cell modules, or that it forms a solar cell module.
  • the solar cell combination according to the invention comprises a plurality of solar cells that are connected and contacted with each other, wherein the solar cells are connected and contacted with at least one first wire conductor that runs (continuously) in the longitudinal direction of successively arranged solar cells, or are connected and contacted with a group of first wire conductors, and are connected and contacted with at least one further contact element or a group of further contact elements so as to form together a solar cell combination, and wherein before or after establishing the electrical connection, the first wire conductors and/or the further contact elements are separated (between the solar cells) such that preferably a series connection is present.
  • a plurality of solar cell combinations formed through separating can be connected and contacted again with each other.
  • the first wire conductor(s) can in each case run from the upper side of a solar cell to the lower side of the adjacent solar cell.
  • the further contact elements are then configured in the form of cross-connectors which are arranged between the lower side of the solar cell and the first wire conductor and which are contacted with the solar cell(s) and the first wire conductor(s).
  • a multiplicity of first wire conductors that are parallel to each other are in each case also contacted on the upper side of the solar cells.
  • the further contact elements are configured in the form of second wire conductors and in the form of cross-connectors, wherein the second wire conductors are contacted on the lower side of the solar cells substantially parallel to the first wire conductors, and wherein transverse to the first and the second wire conductors, at least one cross-connector extends which is preferably contacted in series connection with said first and second wire conductors.
  • the first and second wire connectors are alternately disconnected from the cross-connector.
  • the cross-connector is preferably arranged between the first and second wire conductors and thus is preferably arranged between two adjacent solar cells and perpendicular to the first and second wire conductors.
  • This new contacting and connecting of solar cells by means of two independent electrodes in the form of first and second wire conductors, wherein at least one electrode consists of thin wires that are parallel as far as possible, enables the production of a new generation of solar cell modules.
  • a particular feature here is that different electrode materials and joining technologies can be used for front and back sides.
  • a wire field preferably consists in each case of 10-50 (optimal are approx. 20) wires in almost equidistant arrangement and with a thickness of 50-300 ⁇ m.
  • the cross-section of the wires of the first wire conductors (first electrode) and the cross-section of the wires of the second wire conductor (second electrode) can be different, e.g., round, oval, rectangular, trapezoidal, etc.
  • the wire conductors are made of metal, for example, Cu, Al, Ni, steel, and can be coated, in particular for establishing the connection to the solar cells or to each other, for example, with solder (Sn—Pb, Sn—Pb—Ag, Sn—Bi, etc.), with Ni, or also with an electrically conductive adhesive layer.
  • solder Sn—Pb, Sn—Pb—Ag, Sn—Bi, etc.
  • the connection of the two electrodes is implemented.
  • soldering, glueing or bonding techniques can be used.
  • a particular feature is that, for the first time, different joining technologies can be used for the front and back sides.
  • the contact elements in the form of cross-connectors running in the direction transverse to the wires are used.
  • the cross-connectors are electrically conductive and, for example, can be made of metal or a metal compound.
  • the connection between electrodes (first and second wire conductors) and the contact element/cross-connector can be implemented through a solder-, crimp-, welded or glued connection.
  • the contact element/the cross-connector is preferably arranged between the first and second (both electrodes) wire conductors (in this case between adjacent solar cells) or above or below both of them.
  • the contact elements/cross-connectors can be structured so that later in the module, the light reflected by them is directed through total internal reflection to the active cell surface.
  • coating the contact elements is conceivable such that no reflective and shiny surface is generated, but a diffusely reflecting surface is generated so that likewise a large portion of the reflected light reaches the active cell surface with the result that the efficiency can be further increased.
  • the first wire conductors are arranged above the upper side of the solar cells and the second wire conductors are arranged below the lower side of the solar cells.
  • the second wire conductors are first positioned on a support and subsequently, the solar cells and the cross-connectors are placed thereon and thereafter, the first wire conductors are deposited on the upper side of the solar cells.
  • This still “loose combination” is subsequently connected to each other and contacted.
  • every second wire field in the spaces between the cells is separated or cut out so as to disconnect all connections with identical polarity within the string.
  • Separating/cutting can be carried out, among other things, by means of laser or, in particular, a self-centering cutting device which exerts no forces during cutting on the wires so as to avoid damage to the solar cells.
  • the first continuous wire conductor(s) runs (run) alternately between the upper side and the lower side of adjacent solar cells.
  • the further contact element(s) is (are) configured in the form of one or a plurality of second wire conductors which are substantially parallel to the first wire conductors, wherein the second wire conductor(s) runs (run) alternately opposite to the first wire conductor(s) between the lower side and the upper side of adjacent solar cells.
  • the first and the second wire conductors are preferably separated between the solar cells in such a manner that a series connection is present.
  • a multiplicity of first wire conductors and a multiplicity of further contact elements are provided so that a kind of fabric is formed.
  • the first and second wire conductors are arranged alternately.
  • the first wire conductors and/or the second wire conductors and/or the cross-connectors are preferably configured in the form of a wire having a substantially round or rectangular cross-section, or are configured in the form of a band and have in particular only a very small cross-section. Said very small cross-section is possible here if with one solar cell a plurality of first and/or second wire conductors are contacted.
  • the ends of the first and/or second wire conductors and/or the ends of the cross-connectors are provided with electrical collecting connectors for tapping the current.
  • the first and/or the second wire conductors and/or the cross-connectors are connected to the solar cells in particular in a firmly bonded manner, e.g., by glueing, soldering or welding.
  • first and/or second wire conductors and/or the cross-connectors directly to the solar cells without the need of printing bars (strip conductors) thereon.
  • the solar cell combination into segments by separating the wire conductors or cross-connectors. These segments can be placed offset on top of each other and can be connected so as to form a solar cell module or a module combination.
  • a significant advantage of the solution according to the invention is the ability to standardize interconnections and matrix layout by parallelizing and using suitably wider electrode fields so that unnecessary cell and string handlings can be avoided.
  • Another advantage of the solution according to the invention is due to the fact that the use of expensive materials required for printing the strip conductors can be significantly reduced, or it is possible to completely eliminate the printing of strip conductors since the wire conductors can be connected directly, in particular soldered or glued, to the solar cells.
  • the efficiency of the solar cell modules can be considerably improved compared to conventional solutions. This is in particular possible, when using a multiplicity of wire conductors for each solar cell, through the reduction of shaded surfaces and the increased reflection of the lateral regions of the wires and also through lower internal losses in the solar cell due to an almost full-surface electron collection. Furthermore, it is possible to reduce efficiency losses caused by cell breakage.
  • FIGS. 1 to 6 show the method steps for producing a first variant of a solar cell combination from solar cells by using first wire conductors and further contact elements in the form of cross-connectors running transverse to said first wire conductors, wherein
  • FIG. 1 shows a longitudinal section of solar cells arranged one behind the other and next to each other, onto the upper side of which first wire conductors have been placed, wherein between two successively arranged solar cells, two cross-connectors are placed over the first wire conductor,
  • FIG. 2 shows a three-dimensional view from above of a partial area according to FIG. 1 ,
  • FIG. 3 shows a first row R 1 of solar cells arranged next to each other, which row has been formed by separating the first wire conductors from the solar cells arranged upstream thereof,
  • FIG. 4 shows two rows R 1 , R 2 of solar cells which are to be connected to each other
  • FIG. 5 shows a side view of rows R 1 to R 3 of solar cells, which rows are contacted with each other,
  • FIG. 6 shows a three-dimensional view of a solar cell combination produced according to variant 1,
  • FIGS. 7 to 10 show the method steps for producing a second variant of a solar cell combination from solar cells by using first wire conductors and further contact elements in the form of cross-connectors running transverse to said first wire conductors, and also second wire conductors which are parallel to the first wire conductors and which run on the lower side of the solar cells, wherein
  • FIG. 7 shows a longitudinal section of solar cells arranged one behind the other and next to each other, wherein first wire conductors run in the longitudinal direction over the upper sides of the successively arranged solar cells, and the second wire conductors rest against the lower side of the solar cells, and the cross-connectors run in each case between the first wire connectors and the second wire connectors,
  • FIG. 8 shows a three-dimensional view from above according to FIG. 7 .
  • FIG. 9 shows a solar cell combination according to FIGS. 7 and 8 in a longitudinal section, wherein subsequently the connection between the first and second wire conductors to the cross-connector has been alternately disconnected,
  • FIG. 10 shows the solar cell combination according to FIG. 9 in a three-dimensional view from above
  • FIG. 10 a shows a further variant, similar to FIG. 9 , but with different first and second wire conductors
  • FIG. 10 b shows a schematic illustration of the cutting device
  • FIG. 10 c shows an illustration of a (lower) first wire field F 1 from second wire conductors 3 . 1 ,
  • FIG. 10 d shows an illustration of solar cells 2 positioned on the first wire field F 1 .
  • FIG. 10 e shows an illustration according to FIG. 10 d with cross-connectors 4 .
  • FIG. 10 f shows an illustration according to FIG. 10 e with a second wire field F 2 from first wire conductors 3 ,
  • FIG. 10 g shows an illustration of the separated first and second wire conductors 3 , 3 . 2 ,
  • FIG. 10 h shows an illustration of a solar cell combination with first (upper) wire conductors 3 in the form of thin wires and second (lower) wire conductors 3 . 1 in the form of wide bands,
  • FIG. 10 i shows an illustration of a solar cell combination with first (upper) wire conductors 3 in the form of thin wires and second (lower) wire conductors 3 . 1 in the form of a full-surface film,
  • FIG. 10 k shows the work steps start with an empty carrier, pulling out the back side wires, placing the cells, pulling out the cross-connectors, and pulling out the front side wires,
  • FIG. 10 l shows the transport of the carrier generated on the matrix plate to the heating plate T.
  • FIG. 10M shows an embodiment in which wire conductors are arranged on both sides of the solar cell.
  • FIGS. 11 to 18 show the method steps for producing a third variant of a solar cell combination from solar cells by using first wire conductors which run alternately between the upper side and the lower side of the solar cells, and further contact elements in the form of second wire conductors which are parallel to the first wire conductors and which run alternately opposite to the first wire conductors between the lower sides and the upper sides of the solar cells, wherein
  • FIG. 11 shows a longitudinal section of solar cells arranged one behind the other and next to each other, wherein the first wire conductor runs over the upper side and the lower side of the adjacent solar cells, and the second wire conductor runs oppositely thereto between the lower side and the upper side of the adjacent solar cells,
  • FIG. 12 shows a three-dimensional view according to FIG. 11 from above
  • FIG. 13 shows an enlarged three-dimensional view according to FIG. 11 from above, wherein, however, no printed strip conductors were used,
  • FIG. 14 shows a longitudinal section of solar cells arranged one behind the other and next to each other according to FIG. 11 , wherein the first and the second wire conductors were alternately separated between successively arranged solar cells so that a series connection has been generated
  • FIG. 15 shows a three-dimensional view according to FIG. 14 from above
  • FIG. 16 shows a three-dimensional view of a string according to variant 3 with only one first and one second wire conductor
  • FIG. 17 shows the illustration of a weaving device for producing a solar cell combination according to variant 3.
  • FIG. 18 shows detail X according to FIG. 17 .
  • FIGS. 1 to 6 illustrate the method steps for producing the first variant of a solar cell combination 1 from solar cells 2 by using first wire conductors 3 and further contact elements in the form of cross-connectors 4 running transverse to said first wire conductors.
  • FIGS. 1 and 2 illustrate a first production step wherein a multiplicity of solar cells 2 were placed next to each other and one behind the other onto a non-illustrated support.
  • a multiplicity of first continuous wire conductors 3 were positioned over the solar cells 2 in the longitudinal direction, and cross-conductors 4 were placed transverse to and above the first wire conductors 3 and in each case between a row of successively arranged solar cells 2 and also spaced apart from the successively arranged solar cells.
  • FIGS. 1 and 2 a separating line T is indicated in each case directly before a solar cell 2 .
  • FIG. 2 shows that on the surface of the solar cells 2 , strip conductors 5 are printed transverse to the first wire conductors 3 .
  • the solar cells 2 positioned relative to each other, the first wire conductors 3 and the cross-connectors 4 are now connected to each other and thus contacted, and thus an intermediate combination 1 . 1 is produced. This is preferably carried out through soldering.
  • the first wire conductors 3 are separated along the separating line T so that a plurality of rows R 1 , R 2 . . . of solar cells 2 arranged next to each other are generated which comprise a protruding region B of first wire conductors 3 and two cross-conductors 4 contacted therewith (a first row R 1 is shown in FIG. 3 ).
  • FIG. 4 shows two rows R 1 , R 2 of solar cells 2 which are to be connected to each other.
  • the rows R 1 , R 2 are positioned in such a manner that the two cross-conductors 4 of the region B of the first row R 1 are positioned below the lower side of the solar cells 2 of the following row R 2 .
  • the first row R 1 rests on an assembly support 6 .
  • the second row R 2 is placed in the direction of the arrow onto the assembly support 6 and thus onto the region B of the first row R 1 and thereby onto the cross-conductors 4 of the first row R 1 .
  • the region B of the first row is bent toward the assembly support 6 as shown in FIG.
  • a solar cell combination 1 produced with this first method is illustrated in a three-dimensional view in FIG. 6 .
  • Three rows R 1 to R 3 of solar cells 2 were connected to each other.
  • six first wire conductors 3 are fed to the lower side of the solar cell 2 adjoining in the longitudinal direction.
  • two cross-conductors 4 extend over the solar cell rows R 1 , R 2 and are arranged between the lower sides of the solar cells 2 and the first wire conductors 2 which extend to the lower side of the solar cells (see FIG. 5 ).
  • this combination can also be produced in that in the first method step, the cross-conductors are not contacted over the first wire conductors but are contacted directly on the lower side of a row of solar cells.
  • the first wire conductors 3 are separated such that a plurality of rows are generated and the protruding regions B of the rows are positioned below the lower sides of adjacent solar cells of the adjoining row and are contacted with these solar cells.
  • FIGS. 7 to 10 The method steps of a second variant for producing a solar cell combination are shown in the FIGS. 7 to 10 .
  • longitudinally extending first wire conductors 3 are used.
  • the further contact elements are configured in the form of cross-conductors 4 running transverse to the first wire conductors and to second wire conductors 3 . 1 which are parallel to the first wire conductors 3 and which run on the lower side of the solar cells 2 .
  • FIG. 7 illustrates the longitudinal section of solar cells 2 arranged one behind the other and next to each other, wherein first continuous wire conductors 3 run in the longitudinal direction over the upper sides of the successively arranged solar cells 2 , and second continuous wire conductors 3 . 1 rest against the lower side of the solar cells 2 , and the cross-conductors 4 run in each case between and transverse to the first wire conductors 3 and the second wire conductors 3 . 1 , and run in each case between the successively arranged solar cells 2 .
  • FIG. 8 shows the three-dimensional view from above according to FIG. 7 . It is shown here that the solar cells 2 successively arranged in the longitudinal direction are provided on their upper side in each case with a plurality of continuous first wire conductors 3 and are provided on their lower side with a plurality of second wire conductors 3 which are parallel to said first wire conductors and offset thereto in the transverse direction. It is shown that the cross-conductors 4 extend perpendicular to the first and second wire conductors 3 , 3 . 1 in the transverse direction between them and between the solar cells 2 . Preferably, first the second wire conductors 3 .
  • the solar cells 2 and the cross-conductors 4 , and subsequently the first wire conductors 3 are positioned and subsequently soldered, e.g., in a continuous process, so as to form an intermediate combination 1 . 1 (see FIGS. 7 and 8 ).
  • This intermediate combination 1 . 1 is not yet functional; the desired interconnection has still to be generated by separating the first and seconds wire conductors.
  • the first and second wire conductors 3 , 3 . 1 are alternately disconnected from the cross-conductor 4 .
  • a longitudinal section after separating the connection is shown in FIG. 9 in a longitudinal section and in FIG. 10 in a three-dimensional view from above. Only then, the functional solar cell combination connected in series according to FIGS. 9 and 10 is obtained. Shown therein are the gaps 7 generated in the first and second wire conductors 3 , 3 . 1 through the separation, through which gaps the connection to the cross-conductors is alternately disconnected so that a suitable interconnection between the solar cells 2 and the first and second wire conductors 3 , 3 . 1 has been generated.
  • FIG. 10 a A longitudinal section of a further variant is shown in FIG. 10 a .
  • the first wire conductors 3 (first electrode) and the second wire conductors 3 . 1 (second electrode) are made from different materials and are likewise applied as continuous wires first to both sides of the solar cells, wherein the cross-connectors 4 were positioned between the first and second wire conductors 3 , 3 . 1 and between two adjacent solar cells 2 , and after generating an electrical contact between the first electrode (wire conductor 3 . 1 ) and the back side (here lower side) of the solar cell 2 and also between the second electrode (wire conductor 3 . 1 ) and the front side (here upper side) of the solar cell 2 , the connection of the two electrodes (wire conductors 3 .
  • Cutting out has been carried out, e.g., by means of a laser or, as illustrated, a self-centering cutting device which exerts during cutting no forces onto the wires, as schematically illustrated in FIG. 10 b.
  • the cutting device consists, e.g., of blades S that can be moved in pairs relative toward each other, wherein here a plurality of blades S are provided which, corresponding to the shape of the illustrated first wire conductors 3 to be cut, which have a circular cross-section, are curved at their cutting edges S 1 .
  • the cutting edges S 1 have a concave curvature.
  • the first wire conductors 3 illustrated in grey were cut by the blades S.
  • the cutting edges are preferably implemented substantially linearly (not illustrated).
  • the first wire field F 1 illustrated here with lower second wire conductors 3 . 1 is laid over the entire length of the string or matrix to be produced and is spanned in the longitudinal direction of the wire conductors. After in each case two first wire conductors 3 . 1 which are arranged at a smaller spacing from each other, a larger spacing from the next two second wire conductors 3 . 1 is provided here. Subsequently, the solar cells 2 are positioned with their back sides above said first wire field F 1 ( FIG. 10 d ). If necessary, the contact between the back side of the solar cells 2 and the first wire field F 1 can already be generated.
  • a contact element in the form a cross-connector 4 can be placed ( FIG. 10 e ) so as to implement later the contact between first and second wire fields F 1 , F 2 .
  • the contact elements/cross-connectors 4 have a thickness corresponding to the thickness of the solar cells 2 ; in this manner, no pressure is exerted onto the cell edge of the solar cell 2 .
  • the second wire field F 2 which is formed from first wire conductors 3 running parallel to each other, is arranged and spanned, parallel to the first wire field F 1 , over the upper sides of the solar cells 2 and over the contact elements/cross-connectors 4 , wherein the second wire field F 2 , as illustrated in FIG. 10 f , is arranged offset to the first wire field F 1 .
  • the first wire conductors 3 of the second upper wire field F 2 are illustrated brighter here than the second wire conductors 3 . 1 of the first wire field F 1 located at the bottom here. (The first and second wire conductors 3 , 3 .
  • wire fields F 1 , F 2 can also lie one above the other in a substantially aligned manner—not illustrated here.)
  • the electrical connection between the wire fields F 1 , F 2 and thus between first wire conductors 2 and second wire conductors 3 . 1 and the solar cell 2 , and also between the first wire field F 1 (second wire conductors 3 . 1 ) and the second wire field F 2 (first wire conductors 3 ) and contact element/cross connector 4 is established.
  • different technologies can be used.
  • the separating cut can be carried out mechanically or by means of laser, as described above.
  • a second wire field F 2 from first thin wire conductors 3 . 1 is used on the front side of the solar cells 2 .
  • an optimized low power loss caused by shading and resistance is implemented.
  • second wire conductors 3 . 1 in the form of wider contact ribbons up to the size of bands are used. In this manner, the power losses in the contact structure on the back side can be reduced to a negligible level.
  • FIG. 10 i it is also possible to form the back side contact of the solar cells 2 from a metal film that replaces a plurality of second wire conductors 3 . 1 , which metal film has been designated here also with 3 . 1 and which, e.g., is soldered, glued or fastened with laser welding spots over the full surface on the cell back of the solar cell 2 .
  • One side of the film 3 . 1 protrudes beyond the cell edge of the solar cell 2 .
  • a contact element that is not illustrated here can be applied onto the protruding portion of the film, or the protruding portion of the film is folded without an additional contact element. All this can take place in an upstream pre-production process so that the metal film is already contacted with the back side of the solar cells before being arranged to form the cell combination and is therefore pre-assembled.
  • the prepared wafers are arranged in string or matrix form, and the thin wires in the form of first wire conductors 3 , as in the preceding examples, are positioned as wire field F 2 over the string/the matrix and are contacted with the cell front of the solar cells and with the protruding portion of the film 3 . 1 of the adjacent cell.
  • gaps 7 are also generated.
  • FIG. 10 k shows from left to right the work steps a) start with empty matrix carrier M, b) pulling out the back side wires in the form of a multiplicity of thin second wire conductors 3 . 1 (second electrode) which are aligned substantially parallel to each other, c) placing the cells 2 over the second wire conductors 3 .
  • first and the second wire conductors 3 , 3 . 1 are arranged parallel to each other and are aligned here one above the other, and are present in the same quantity.
  • the matrix carrier M loaded according to FIG. 10 is transferred from the first work station to a second work station.
  • the latter is characterized by a structured heating plate T into which negative structure elements on the back side of the matrix carrier fit, see FIG. 10L .
  • the heating plate T and the matrix carrier M By structuring the heating plate T and the matrix carrier M, the latter can be made very thin and thus in a highly heat-conducting manner underneath the solar cells—possibly facilitated by a black anodized layer—while the webs on the back side ensure the necessary mechanical stiffness and also increase the surface area for the heat transfer.
  • the heating plate T is heated to a temperature close to but below the melting temperature of the solder. After a short heating period, the electrodes are soldered together with the solar cells and the cross-connectors and as a result, contacting of a multiplicity of solar cells with first and second wire conductors and cross-connectors is established in only one step.
  • a multiplicity of thin second wire conductors a few metal bands or a metal film can also be used as a second electrode.
  • separating the electrodes can already be carried out in the second work station, e.g., parallel to or with a delay to the soldering process. Subsequently, the matrix carrier is transported to a non-illustrated third work station.
  • the latter can be provided with a cooling plate analogous to the second work station so as to accelerate cooling of the matrix carrier. In this work station—if not carried out in station 2 —separating the wire fields takes place.
  • the embedding material e.g., EVA
  • the module glass plate can subsequently be deposited and fixed on the carrier. Thereafter, the carrier together with the matrix, the embedding material and the glass is turned, the fixation of the glass is released and the carrier is lifted. For further processing, the module glass plate is then further treated in a conventional manner (e.g., applying the second layer of EVA and the back film and laminating). Through this it is avoided that the matrix has to be transported by means of grippers, vacuum suction cups or Bernoulli grippers.
  • An advantage of this arrangement is the parallelization of the time-consuming work steps such as the cell positioning and the soldering process. This also reduces the residence time on the heating plate.
  • the cell matrix together with the sensitive solder joints and the thin electrodes are always supported by the matrix carrier or, in the further course, by the glass plate.
  • the first and/or second wire conductors are separated between the solar cells after contacting in the matrix carrier so that the desired interconnection is created. This is preferably carried out in the matrix carrier or in a further device with a suitable cutting/separating unit.
  • FIG. 10M shows an exemplary embodiment in which the first and second wire conductors 3 , 3 . 1 , which are arranged on both sides of the solar cell 2 , have been directly connected to each other and have been provided with suitable gaps 7 by separating the wire conductors.
  • This variant has the advantage that the cross-connectors can be eliminated.
  • FIGS. 11 to 18 illustrate the method steps and a device for producing a further variant of a solar cell combination 1 from solar cells 2 by using first wire conductors 3 which run alternately between the upper side and the lower side of the solar cells 2 and using further contact elements in the form of second wire conductors 3 . 1 which are parallel to the first wire conductors 3 and which run alternately opposite to the first wire conductors 3 between the lower sides and the upper sides of the solar cells 3 .
  • FIG. 11 illustrates the longitudinal section of solar cells 2 arranged one behind the other and next to each other, wherein a continuous first wire conductor 3 runs over the upper side and the lower side of the adjacent solar cells 3 , and the continuous second wire conductor 3 . 1 runs opposite thereto between the lower side and the upper side of the adjacent solar cells 2 , and the three-dimensional view according to FIG. 11 is illustrated from above in FIG. 12 .
  • the solar cells are provided on their upper side with strip connectors 5 which are printed thereon transverse to the first and second wire conductors.
  • FIG. 13 illustrates an intermediate combination 1 . 1 on which no strip connectors are printed, as a result of which the manufacturing complexity is decreased and costs are considerably reduced.
  • FIG. 14 shows a longitudinal section and FIG. 15 shows the three-dimensional view of solar cells 2 arranged one behind the other and next to each other, wherein alternately between successively arranged solar cells 2 , the first and second wire conductors 3 , 3 . 1 were separated so that through the gaps 7 generated during separating (preferably by means of laser), a series connection is formed and the desired solar cell combination 1 is created.
  • FIG. 16 illustrates the three-dimensional view of a string S produced according to variant 3 with solar cells 2 which were contacted with only one first and one second wire conductor 3 , 3 . 1 .
  • FIG. 17 shows the schematic diagram of a device 10 for producing a solar cell combination or an intermediate combination according to variant 3, and the detail according to FIG. 17 is shown in FIG. 18 .
  • a multiplicity of first wire conductors 3 arranged next to each other and a multiplicity of wire conductors 3 . 1 arranged therebetween are fed to the weaving device 12 .
  • the wire conductors 3 , 3 . 1 are alternately moved upward and downward according to the arrow by means of weaving rolls 13 , 14 .
  • a row of a plurality of solar cells 2 is inserted by means of a cell handling device 15 and moved in the transport direction and subsequently, the first and second wire conductors 3 , 3 . 1 are spanned around.
  • a downholder 16 is provided which keeps the wire conductors 3 , 3 . 1 in the extension plane of the solar cells 2 during the weaving process.

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CN108258074A (zh) 2018-07-06
DE112010005605A5 (de) 2013-06-20
US9246042B2 (en) 2016-01-26
KR20130086960A (ko) 2013-08-05
JP6014586B2 (ja) 2016-10-25
JP2013527616A (ja) 2013-06-27
CN108258074B (zh) 2021-06-08
CN103038896B (zh) 2018-02-23
EP2577740B1 (de) 2018-11-14
WO2011147388A1 (de) 2011-12-01
US20130183789A1 (en) 2013-07-18
EP2577740A1 (de) 2013-04-10
CN103038896A (zh) 2013-04-10

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